Electret webs with charge-enhancing additives
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Solution Overview
Problem
There is a need for electret webs with improved properties that can be easily charged through various mechanisms such as tribocharging, corona discharge, or hydrocharging, and can function effectively as filter media without requiring additional charging methods.
Innovation Solution
The development of electret webs comprising a blend of a thermoplastic resin and a charge-enhancing additive, specifically a divalent metal-containing substituted-mercaptobenzimidazolate salt, which allows for enhanced charging capabilities, particularly through DC corona discharge alone, and is suitable for use in filtration media.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electret webs are used without charge-enhancing additives, then the manufacturing process is simpler, but the charging efficiency and filtration performance are insufficient
Solution Approach 1:
The patent applies composite materials by combining thermoplastic resin with charge-enhancing additives (divalent metal-containing substituted-mercaptobenzimidazolate salts) to create an electret web with enhanced charging efficiency and filtration performance. This composite approach allows the material to achieve superior electret properties while maintaining processability through conventional manufacturing methods.
2Reliability
If multiple charging mechanisms are required to achieve sufficient filtration performance, then the filtration efficiency improves, but the device complexity and processing steps increase
Solution Approach 1:
The charge-enhancing additives embedded in the electret web enable the material to self-charge effectively through conventional charging mechanisms (tribocharging, corona discharge, or hydrocharging). The additives enhance the charging efficiency so that a single charging mechanism is sufficient to achieve the desired filtration performance, eliminating the need for multiple charging steps.
3Reliability
If additional charging methods are applied to improve filtration performance, then the electret charge increases, but the manufacturing complexity and energy consumption increase
Solution Approach 1:
The patent modifies the chemical composition parameters of the electret web by incorporating charge-enhancing additives. This compositional change increases the charging efficiency, allowing the material to achieve higher electret charge with lower energy input from a single charging mechanism, thereby reducing overall energy consumption compared to applying multiple charging methods to conventional electret webs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The electret webs demonstrate improved filtration performance, as evidenced by higher Quality Factor values and increased % Penetration Ratio after X-ray discharge testing, indicating effective electrostatic charging and enhanced particle capture capabilities.
Implementation Method 1
The electret webs may be charged by any convenient mechanism such as, for example, tribocharging, corona discharge, hydrocharging or a combination thereof
Implementation Method 2
The electret webs may be charged by any convenient mechanism such as, for example, tribocharging, corona discharge, hydrocharging or a combination thereof
Implementation Method 3
The electret webs may be charged by any convenient mechanism such as, for example, tribocharging, corona discharge, hydrocharging or a combination thereof
Implementation Method 4
electrets are effective in enhancing particle capture in aerosol filters
Data Source
AI summary
Electret webs include a thermoplastic resin and a charge-enhancing additive. The charge-enhancing additive is a divalent metal-containing substituted-mercaptobenzimidazolate salt. The electret webs may be a non-woven fibrous web or a film. The electret webs are suitable for use as filter media.